Method of gas, oil and mineral production using a clean processing system and method

ABSTRACT

The invention provides a system and process for providing a clean, non-contaminating process, for producing fracturing of shale, limestone, sands and other geological and mining formations to release natural gas, oil and minerals within a formation. A system used in the process produces on site the energy required to induce fracturing, removing natural gas and oil, and to recycle fluids used in fracturing for additional use. Removable storage provides the necessary materials to provide fracturing, removal and processing of the fracturing liquids for addition use at one or more sites, and to provide processing, storage and transportation of the resulting natural gas and oil.

FIELD OF THE INVENTION

The invention relates to a method and system for producing fracturing ofshale and oil sands, and mineral containing material to release naturalgases and oil utilizing CO₂ and a steam process without using otherchemical contaminants.

BACKGROUND OF THE INVENTION

Most fracturing processes use various chemicals in their process torecover gas and oil. For example, U.S. Pat. No. 8,733,439 uses CO₂, butalso used H₂O₂ (hydrogen peroxide) which, when used medically in smallamounts, is considered a mild antiseptic, and can be used as a bleachingagent. Hydrogen peroxide can be used for certain industrial orenvironmental purposes as well, because it can provide the effects ofbleaching without the potential damage of chlorine-based agents. Becausethis substance can be unstable in high concentrations, it must be usedwith care. In higher concentrations, it can create strong chemicalreactions when it interacts with other agents, and it can damage theskin or eyes of persons working with it. The use in wells maycontaminate underground water if there is seepage into ground water.This patent also uses other chemicals such as Fe, Co, Ni and similarchemicals.

Other processes also use various chemicals, particulate material, andother catalysts which can contaminate water sources such as wells andaquifers. These processes utilize a large amount of water which often isnot or cannot be recycled because of the toxic chemicals containedtherein.

SUMMARY OF THE INVENTION

An object of the invention is to provide a clean, non-contaminatingprocess for producing fracturing of shale, limestone, sands, and othergeological and mining formations to release natural gas and oil within awell, and to break up any mineral containing material.

Another object of the invention is to provide a system to produce onsite the energy required to induce fracturing, removing natural gas andoil, and to recycle fluids used in fracturing for additional use.

Another object of the invention is to provide for movable storage offracturing liquids for additional use at one or more sites.

The technical advance represented by the invention as well as theobjects thereof will become apparent from the following description of apreferred embodiment of the invention when considered in conjunctionwith the accompanying drawings, and the novel features set forth in theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a diagram of the basis system of the invention andthe process associated therewith.

FIG. 2 illustrates additional features which may be utilized with thepresent invention.

FIG. 3 illustrates a well configuration in which frozen CO₂ is insertedinto a well and then expanded by pressurized steam to cause fracturingof the walls of the well.

FIGS. 4 a and 4 b illustrate two types of insertion tubes.

DESCRIPTION OF A PREFERRED EMBODIMENT

FIG. 1 illustrates the system and method for producing clean fracturingin a natural gas and oil well. The well has a vertical drill bore and orpipe casing 1 a and a horizontal drill bore or pipe casing 1 b extendinghorizontally from the lower end of vertical drill bore and or pipecasing 1 a. This is the standard method of drilling wells. Inserted inthe well is vertical pipe or tube 2 a which extends the length ofvertical well bore 1 a and then extends horizontally, 2 b, into thehorizontal well bore 1 b. Well bore 1 a is then caped at the top withseal 15. This is to prevent any gasses or other material from escapingout into the atmosphere and surrounding area. This system is an examplethat can be used with the claimed fracturing process. Modification ofthe system and other configurations may be used with the fracturingprocess.

The rest of the system is described as follows. Clean water is suppliedthrough input 14 through a processing system 8, which includes a threeway valve. The water is directed through 23 into pipe 9 and then in tostorage container 5, which carbonates the water, using the CO₂ fromportable storage container 6.

The carbonated water from container 5 is then directed, through pipe 10and valve 10 b, into the well at opening 10 a. This carbonated waterflows downward into the well and fills the horizontal portion 1 b withcarbonated water. The carbonated water in container 5 may berefrigerated to keep the carbonated water cool, or partially frozen soas to prevent vaporization of the CO₂ from the water while it is beinginjected into the well. The carbonated water may be lightly frozen toprovide an icy slush. Sand can be injected into the wellbore alone, orwith the carbonated water to aid in the fracturing process.

Once the well, particularly the horizontal portion 1 b is filled withthe carbonated water, then pressurized steam, generated in steamgenerator 4, is injected into the well though valve 3 into pipes ortubes 2 a and 2 b. Pipe/tube 2 b has openings 16 around it periphery andalong its length to distribute the steam throughout horizontal well bore1 b. The pressurized steam causes the carbonated water to literallyexplode creating a great pressure in the well causing fracturing of thewalls of the well bore, thus releasing natural gas/oil from theunderground sources. To keep all of the pressurized steam from exitingthough the first holes at the beginning 2 c of horizontal pipe 2 b,there are fewer holes at the start of horizontal pipe 2 c to preventexiting of a large quantity of pressurized gas. The number of holesincreases towards the 2 d end of the horizontal pipe. This progressiveincreasing of holes helps to evenly distribute the pressurized gasthroughout the horizontal portion 1 b of the well.

After the fracturing process, the remaining carbonated water, any loosesand, and the gas/oil is then pumped upward though well bore 1 a andpipe 2 a through pipes 11 a and 11 b to valve 11 c and though pipe 11into processing unit 7, which may have storage capacity. Processing unit7 filters out any particulate material and separates the gas/oil and CO₂from the remaining water. The CO₂ can be returned through pipe 28 to theCO₂ storage tank 6 for reuse. The gas/oil is then stored or directed outpipe 13 for storage and/or transportation to another storage facility.

To prevent the particulate filter 7 from becoming clogged withparticulate material, there could be at least two parallel particulatefilters. One would be used at a time. When the flow of gas/petroleum/CO₂decreases to a lower determined level through the particulate filter, asensor would detect this lower level and would switch the flow through aparallel filter. There would be a notification of this change, and theclogged filter could be cleaned to remove the particulate for use again.

The separated water is then passed through pipe 12 into processingsystem 8. The water can be directed back into the system though valvefor reuse, as needed, for additional fracturing of the well. The watercan also be processed to clean it, removing any and all chemical and/orforeign matter from the well and then sent thought pipe 14 for storageand/or another use.

All of the units, Steam generator 4, carbonated water unit 5, CO₂ unit6, separator 7 and processing system may all be portable units for useat other locations. The units may be incorporated in one movable unitfor movement to other drilling sites.

To prevent excess pressure that would cause over fracturing in the well,a pressure sensor 30 measures the pressure. If the pressure exceeds apredetermined amount, then release valve 31 would open, and stay open,as long as the pressure exceeds the predetermined amount. When thepressure is reduced, then value 31 would close.

As an alternative to using carbonated water, refrigerated CO₂ can beinjected into the well bore and then expanded with the pressurizedsteam. This would limit the amount of carbonated water needed in thewell bore. Since steam is vaporized water, after the steam is injectedinto the refrigerated CO₂, it would cool and become carbonated water.Additional steam injected into the refrigerated CO₂ would cause it toexpand and cause fracturing. This would limit the amount of carbonatedwater to be removed from the well for cleaning and future use.

FIG. 2 illustrates the system and method for producing clean fracturingin a natural gas and oil well as in FIG. 1 with the followingdifferences in the system and method. In the vertical part of thewellbore 1 a, a isolation plug 19 is placed near the bottom of thevertical portion 1 a of the well bore, or in any part of horizontal wellbore 1 b. The location of the isolation plug is determined where thefracturing of the well is to begin. Since carbonated water cannot beinserted into the well after the isolation plug seal 19 is in place, thevalve 3 of FIG. 1 is replaced with valve 20. The carbonated water isthen passed through pipe 17 into valve 20 into pipe 2 a to insert thecarbonated water into the well bore. The carbonated water will flowdownward through pipe 2 a and horizontal pipe 2 b and into the well outopenings 16 and out the end 2 d of horizontal pipe 2 b into the wellbore. The pressurized steam from steam generator 4 is directed throughvalve 20 into pipe 2 a and 2 b. The steam is then evenly distributedinto horizontal well bore 1 b through openings 16, as in FIG. 1,providing pressure to producing the fracturing required to release thenatural gas or oil from the surrounding areas. The advantage of usingisolation plug 19 is that the pressure cannot pass upward into verticalwell bore 1 a, or unwanted areas of 1 b, providing a greater pressure inthe localized horizontal portion of 1 b of the well bore, increasing thefracturing pressure and increasing the result of the fracturing,releasing more natural gas and/or oil.

Isolation plug 19 could include a pressure sensor 38 and release valve39 to prevent the pressure from exceeding a predetermined amount, toprevent over fracturing. The isolation plug can be later removed ordrilled out to allow flow in well bore 1 a.

After the fracturing process, the remaining carbonated water, any loosesand or other particulate material, and the gas/oil may be pumped upwardthough pipe 2 a and well bore 1 a through pipes 11 a and 11 b to valve11 c, and then through pipe 11 into processing unit 7.

FIG. 3 illustrates a well configuration in which frozen CO₂ is insertedinto a pipe 45 and then expanded by pressurized steam to causefracturing of the walls of the well bore 1 b. This configurationinvolves cooling CO₂ in unit 50 to below its freezing temperature of−109.3 degrees F. and injecting a snow like compound into well bore 1 b.This is achieved through a flexible composite material or metal alloyinsertion hose or tube 51 and tube 45, which can be the same as tube 2a, FIG. 2, attached via a delivery hose or tubing from the surface. Thecooled CO₂ is released into the well bore through the perforations 43 inthe insertion tube 42, or by use of, or with a perforating gun. Whensufficient amounts of cooled CO₂ are achieved, a CO₂ sensor and releasevalve 41 immediately closes off the CO₂ induction and triggers a steampressure sensor and release valve 40 for high pressure steam toimmediately be injected through the same flexible perforated compositeor metal alloy insertion tube 45. A pressure containment plate 46 sealsthe lower portion of the well to prevent pressure from rising upward tothe top of the well. This process creates a catalytic reaction thatrapidly heats and expands the cooled CO₂ causing the fracturing of theshale or other geological formation being addressed. This process can becarried out in one large stage or in multiple stages, depending upon thespecific characteristics of the geological formation being fractured,and can be repeated until the required desire of fracturing is achieved.This configuration can be used in combination with the basic systemshown in FIG. 2 where the assembly in FIG. 3 replaces the structure atthe lower end of tube 2 a, or any part of horizontal 1 b of FIG. 2.

Pipe 45, in FIG. 3 may have several configurations and partitions forinserting the fracturing materials into the well. FIGS. 4 a and 4 bbelow, shows two possible configurations. Other configurations arepossible to individually insert the fracturing materials in the ordernecessary to provide the fracturing.

The carbonated water, frozen CO₂, and steam are alternately insertedthough valve 20 a.

The system of FIG. 1 could be used to extract minerals other than gasand oil. In this configuration, there would be extreme fracturing tobreak up the mineral containing soil/rock in the structure. The mineralcontaining soil/rock would be vacuumed up out of the structure where theminerals could be separated from the soil/rock. This process would use avacuum system similar to that used to mine minerals from the sea bottom.In this instance, the pressure system and release valves would not beused.

FIGS. 4 a and 4 b illustrate two types of insertion tubes. FIGS. 4 a and4 b are cross sectional views taken at A-A in FIG. 3.

FIG. 4 a shows concentric used to insert particulate frozen CO₂,pressurized steam and carbonated water and fracking sand as needed. Theouter structure is the well bore structure into which the concentrictubes are inserted.

FIG. 4 b shows parallel tubes into which pressurized steam, carbonatedwater and particulate frozen CO₂ are injected into the well borestructure.

These two configurations are examples for inducing the fracturingmaterial. Other configurations may be used, for example some of thetubes may be used for more than one insertion path, different injectionmaterials may be switched between the injection paths.

The valves 3, 20, 20 a, 10 b and 11 c and tubes 2 a and 2 b in FIGS. 1,2 and 3 may remain onsite for future use.

What is claimed:
 1. A method of providing fracturing in a well bore, toproduce at least one of natural gas and oil, having vertical andhorizontal well bore regions, injecting carbonated water into the wellbore; and injecting pressurized steam into the carbonated water to causefracturing of the walls of the well.
 2. The method according to claim 1,wherein the well bore has vertical and horizontal portions and a pipe inthe well extends into the vertical and horizontal portions of the wellbore; Wherein, pressurized steam is injected into the horizontal regionof the well bore though peripheral openings in the pipe in thehorizontal region of the well bore; and Fracking sand is inserted asneeded.
 3. The method according to claim 1, wherein the carbonated wateris refrigerated prior to injecting it into the well.
 4. The methodaccording to claim 1, wherein at least one of natural gas and oil, thecarbonated water, and any released CO₂ are removed from the well, thecarbonated water and CO₂ being separated from at least one of naturalgas and oil, and processed for further use.
 5. The method according toclaim 1, wherein a seal is placed in the well bore to limit thepressurized region of the well bore to increase the pressure therein,thereby increasing the fracturing pressure; and at least one pressuresensor and pressure release valve is placed in the well to prevent thepressure produced by the carbonated water and pressured steam fromexceeding a predetermined value.
 6. A method of providing fracturing ina well bore, to produce at least one of natural gas and oil; injectingat least one of refrigerated carbonated water and frozen CO₂ into thewell; injecting pressurized steam into a region of the well bore thoughperipheral openings in a pipe extending downward into the well bore andinto the horizontal region of the well bore.
 7. (canceled)
 8. The methodaccording to claim 6 wherein the CO₂ is cooled below its freezingtemperature to produce a snow like material which is injected into thewell bore through a tube and is released into the well bore throughperforations in the tube; and injecting pressurized steam after asufficient amount of cooled CO₂ is released into the well to create acatalytic reaction that heats and expands the cooled CO₂ causing thefracturing of shale and other geological formations in the well.
 9. Themethod according to claim 8 including the triggering of a sensor valvewhen a sufficient amount of cooled CO₂ has been released into the wellbore to close off the insertion of cooled CO₂ and opening a second valveto allow pressurized steam to be injected into the well to rapidlyexpand the cooled CO₂.
 10. A system for producing fracturing in a wellbore utilizing only carbonated water, sand as needed, and pressurizedsteam, comprising: a well bore having a vertical and horizontal region;a pipe extending downward in the vertical region and horizontally in thehorizontal region; a storage unit for holding carbonated water forinjection into the well; a steam generator for injecting pressurizedsteam into the carbonated water for producing fracturing in the well;and a pumping unit for removing at least one of gas and oil releasedduring the fracturing process.
 11. The system according to claim 10,including a unit for refrigerating the carbonated water prior to beinginjecting into the well bore.
 12. (canceled)
 13. The system according toclaim 10, wherein the perforated openings in the horizontal portion ofthe pipe are spaced apart at different intervals along the horizontalportion of the pipe to evenly distribute the pressurized steam equallyalong the length of the horizontal portion of the pipe.
 14. The systemaccording to claim 10, including an isolation plug to prevent thepressurized steam, contaminates and carbonated water from moving up thevertical portion of the well, increasing the pressure in any portion ofthe well bore to produce greater fracturing in the well.
 15. The systemaccording to claim 10, including a seal at the top of the well toprevent any gases and other materials from leaving the well and enteringthe atmosphere.
 16. The system according to claim 10 including: aseparator for separating any remaining carbonated water from gas and oilin the well; and a processing system for cleaning the carbonated waterremoved from the well.
 17. The system according to claim 10, where anymaterials removed from the well bore pass through a particulate filterto remove particulate material from fluids removed from the well. 18.the system according to claim 17, wherein the system includes at leasttwo particulate filters, only one filter being used at a time so thatthe one that is not being used can be cleaned for future use.
 19. Thesystem according to claim 10, including a system for freezing CO₂ forinjecting into the well bore.
 20. The method according to claim 1,wherein CO₂ is injected into the well bore instead of carbonated water,and the CO₂ is expanded by the pressurized steam to cause fracturing.